Process for producing a stent for angioplasty

ABSTRACT

A stent has surface sculpturing, preferably on its outer surface only, having, for example, microspheres, having the function of increasing the actual geometric surface area of the stent, of creating undercuts and roughness to encourage the application of coatings of active or activatable agents, as well as of improving the attachment of the stent to the blood vessel wall.

This application is a continuation of application Ser. No. 11/691,933, filed Mar. 27, 2007 now U.S. Pat. No. 7,739,781 B2, which is a continuation of application Ser. No. 10/431,557, filed May 7, 2003, now U.S. Pat. No. 7,607,208 B2, issued Oct. 27, 2009, which is a continuation of application Ser. No. 08/997,597, filed Dec. 23, 1997, now U.S. Pat. No. 6,638,302 B1, issued Oct. 28, 2003, the contents of each of which are hereby incorporated herein by reference.

FIELD OF THE INVENTION

The present invention concerns a stent for angioplasty and an associated method of production thereof.

BACKGROUND OF THE INVENTION

The term “stent for angioplasty” is intended to indicate generally devices intended for endoluminal application (for example, within a blood vessel) in association with the technique of percutaneous transluminal coronary angioplasty, or PTCA, usually effected by catheterisation of a stenotic site.

Expanding the stent at the site causes the lumen to expand giving rise to the consequent elimination of the stenosis, and the local support of the lumen by the stent, which is left in place expanded, avoids restenosis of the treated site due to the subsequent relaxation of the blood vessel wall. The use of a substantially similar structure for deploying vascular grafts and fixing them in place has already been proposed in the art: naturally, this possible extension of the field of application should be seen as included within the ambit of the present invention.

For a general review of vascular stents, reference may usefully be made to the work “Textbook of Interventional Cardiology” edited by Eric J. Topol, W.B. Saunders Company, 1994 and, in particular, to section IV of volume II, entitled “Coronary Stenting”.

Many patent documents have addressed this problem, for example, U.S. Pat. No. 4,776,337, U.S. Pat. No. 4,800,882, U.S. Pat. No. 4,907,336, U.S. Pat. No. 4,886,062, U.S. Pat. No. 4,830,003, U.S. Pat. No. 4,856,516, U.S. Pat. No. 4,768,507 and U.S. Pat. No. 4,503,569.

The implantation of these devices, which is a factor in the treatment of various cardiac diseases, may require, or at least gain particular benefit from the possibility of being able to administer at the stent-implantation site agents or active principles (the two terms being used below in an equivalent sense) having various end purposes: they may, for example, be antithrombogenic agents or, more generally, agents for directly resisting restenosis of the treated site due to the formation of deposits, tissue proliferation, etc. In relation to this, reference may usefully be made to the following works:

“Local Drug Delivery: The Development of a Drug Delivery Stent” by Richard Stack, The Journal of Invasive Cardiology, Vol. 8, n. 8, October 1996, pp 396-397;

“Local Intraluminal Infusion of Biodegradable Polymeric Nanoparticles” by Louis A. Guzman et al., Circulation, 1996; 94; pp 1441-1448;

“Local Angiopeptin Delivery Using Coated Stents Reduces Neointimal Proliferation in Overstretched Porcine Coronary Arteries” by Ivan De Schreerder et al., the Journal of Invasive Cardiology, Vol. 8, n. 8, October 1996, pp 215-222.

Many applicational problems arise from this mode of operation, mostly related to the specific solutions adopted. For example, the problem exists of avoiding the agent or agents intended for administration in the zone of the stent being delivered or transported to different areas where they may have negative or damaging effects. Other problems may arise, for example, in ensuring the permanence and the gradual release over time of active substances capable of being, as it were, washed away by the blood passing through the stent.

These problems cannot themselves be solved or avoided by recourse to other solutions such as radioactive stents or so-called biodegradable stents, as illustrated, for example, in the work “Biodegradable Stents: The Future of Interventional Cardiology?” by M. Labinaz et al; Journal of International Cardiology, Vol. 8, n. 4, 1995, pp 395-405. Radioactive stents publicly proposed so far give rise to other problems related essentially to the fact that, in most cases, their use assumes the typical features of radiotherapy and/or nuclear medicine. The main disadvantage of biodegradable stents is that, at least in the long term when the stent has completely or substantially degraded, there is a reduction in the mechanical support of the blood vessel wall against the risk of collapse.

As a further solution for administering various kinds of active principle at the stent-implantation site a solution has recently been proposed in which at least a portion of the surface of the body of the stent (or implantation device in general) is coated with a receptor capable of binding with a ligand formed by combining an active principle with a substance capable of binding to the receptor.

In order for this new solution to be fully beneficial, that is, so that it can also be used with more conventional techniques for effective topical administration of the active principles, it appears important to obtain a good adhesion and/or retention on the stent of the substance or substances with which these active principles are associated and/or are intended to be associated.

In relation to this it is therefore necessary to take account of various concomitant factors which often oppose one another.

In a significant number of applications it is important that the active principles are present mainly, although not exclusively, on the outer surface of the stent. Conversely, it is usually desirable that the inner surface of the stent itself is as inert as possible, that is, both from the chemical point of view and from the point of view of the possible mechanical anchorage of possible deposits.

This is the reason why currently available vascular stents are subjected to a polishing process, intended to make the surface of the stent (both inside and outside) very smooth. In relation to this, it is also possible to coat the stent with a layer of biocompatible material, such as a biocompatible carbon material (deposited, for example, using sputtering techniques), so as to confer a high degree of hemocompatability on the whole stent. Adopting this technique for the deposition of such a layer, given the very small dimensions of a stent for angioplasty, means that it is practically impossible to limit the deposition to just the inside surface of the stent. Consequently therefore, the entire surface of the stent is coated with a layer which, by its nature, makes the deposition of substances on the stent itself, in fact, impossible.

A further factor should not be forgotten: a stent for angioplasty is by its nature a heavily apertured structure, usually a mesh-like structure in which, especially in the radially-extended position, the effective surface intended to come into contact with the blood vessel wall is a small fraction of the theoretical tubular surface area defined by the outside of the stent itself. In other words: even by putting the other problems described above to one side, there is very little available surface on the stent for carrying the active principles intended for local delivery.

The object of the present invention is that of resolving the disadvantages described above.

In particular, the solution according to the invention, having the characteristics referred to in the following claims, enables the selective application, specifically to the outer surface only of the stent, of a completely effective quantity of active principle (either directly or in the form of a receptor capable of binding with a ligand carrying the active principle) without by this losing the possibility of having a very smooth surface, at least inside the stent, even if clad with coatings such as haemocompatible carbon coatings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 to 6 are partial enlarged views of a segment of a stent in transverse section secondary to various embodiments of the invention.

DETAILED DESCRIPTION OF THE INVENTION

The invention, which concerns a stent as well as the associated procedure for the manufacture thereof, will now be described with reference to the accompanying drawings, comprising FIGS. 1 to 6, which illustrate different possible embodiments of the invention.

In all of the accompanying Figures, the reference numeral 1 indicates a wall portion of a stent for angioplasty. By way of example, FIGS. 1 to 6 can be considered as partial views on an enlarged scale of a segment of a stent in transverse section. Such a section is usually circular in shape regardless of whether the stent is radially-contracted or radially-expanded.

The specific details of construction of the stent and, in particular, its geometry, are factors which are in themselves clear in the context of the invention and which apply regardless of the particular structure of the stent. This is also substantially true as regards the basic manufacturing technique (for example, starting from a wire or microtube which is then subjected to an operation for cutting the apertures, for example, using lasers) and/or the material (usually metal) of which the stent is made. All of these factors are dealt with in a fairly large volume of literature and do not require detailed description here.

In essence, the invention provides for the formation of surface sculpturing on the stent 1, at least—and preferably—over a part of, or the whole of the outer surface, indicated 2, and having substantially the aim of:

-   -   increasing the theoretical surface area of the stent in order to         encourage the application of coatings, such as those intended to         carry or bind active principles,     -   creating in any case undercuts and roughness so as to form         anchorage sites for the substances, without requiring specific         surface-adhesion sites, and, as a complementary advantage,     -   improving the attachment of the stent to the blood vessel wall         that is already in the acute phase, specifically by preventing         relative movements which can give rise to microlesions.

For clarity, the term “sculpturing” is used to distinguish clearly the surface conformation attributed to the stent according to the invention from the degree of surface (residual) roughness that the surfaces of the stent have in any case, even when they have been previously subjected, according to convention, to a polishing or finishing process.

By way of example, one such treatment confers such a degree of residual roughness on the stent surfaces that the peak-to-trough distances recognisable in a theoretical section of the surface in question at right angles to the surface itself are not, in any case, greater than approximately 2-3 microns.

The degree of surface irregularity, or sculpturing, characteristic of the invention is, instead, such that the peak-to-trough distances found in similar conditions are, typically approximately 10-20 microns, that is, with the possibility of achieving values of an order of magnitude even greater than those of the normal surface finishing of a stent.

FIGS. 1 to 6 illustrate, in order of current preference, different techniques that can be used to confer the desired degree of sculpturing on the surface 2.

In particular, FIG. 1 concerns the application of microspheres 3 formed from the same material (usually metal) as the stent or from different materials with the subsequent anchorage of the microspheres (the average diameter of which is approximately 10-20 microns) using the method known as “hot partial melting”. This is a method known in the art and is used, for example, to confer a surface appearance approximately similar to the surface appearance characteristic of a work-piece obtained by sintering the surfaces of mechanical work-pieces intended for various purposes. From this one understands that such an embodiment can be practised also in connection with a stent realized, as a whole, or at least in those part(s) corresponding to the surface sculpturing, by sintering.

FIG. 2 concerns an embodiment of the arrangement illustrated in FIG. 1 in which, while retaining the same typical surface irregularity, irregular-shape granules 4 are used in place of the microspheres 3. The same remarks made in the foregoing in respect of possibly manufacturing the stent, at least partly, by sintering apply also in this case.

FIG. 3 illustrates a further embodiment based on the deposition of a receptor material using, for example, sputtering or plasma spray techniques to form an irregular-shape accretion, for example, having a pseudocolumnar structure.

From this point of view, the solution according to FIG. 1 (the application of microspheres) seems to be preferred when it is desired to create undercuts and roughness on the surface 2, having a mechanical anchorage function and precisely defined geometric characteristics which are identified by the (precisely determinable) grain size of the microspheres 3.

Conversely, the arrangement shown in FIG. 3 appears preferable where the objective is to maximise the effect of increasing the theoretical surface area that is effectively exposed. This latter solution is therefore preferred when, for example, it is desired to apply a coating to the surface of the stent 1, which coating transports and/or is intended to transport active principles and is essentially in the form of a monomolecular layer.

The arrangement according to FIG. 2 constitutes, to a certain extent, a kind of intermediate between the arrangements of FIGS. 1 and 3.

The arrangements to which FIGS. 1 to 3 refer, which comprise possible equivalent arrangements, are characterised essentially by the fact that the surface sculpturing is formed by the application to the surface 2 of material identical with or different from that of the stent 1. These arrangements are generally preferred when greater or smaller undercut zones are desired on the surface 2.

In any case, objects substantially similar to those described at the beginning of this detailed description of the invention can be achieved by treating the surface 2 in ways intended to confer a generally sculpted appearance thereon.

In relation to this, FIG. 4 illustrates the results obtained by subjecting the outer surface 2 to sand-blasting or shot-blasting (a term reserved for a treatment which—instead of using sand as in sand-blasting—is effected using microspheres (“balls”) as the ballistic agents, for impact with the treated surface).

FIG. 5 illustrates the results of a mechanical scoring operation (incision or knurling) performed on the outer surface 2 of the stent.

Finally, FIG. 6 illustrates the results obtained from a localised chemical attack (etching) of the surface 2. This method is effected using a resist material (for example, photoresist) which, following exposure through masks or polymerisation using laser beams, is selectively removed from some zones of the surface 2 so as to enable the attack thereof. The resist tracks remaining on the surface 2 are then removed by washing.

This technology is well known in the art (for example, for the manufacture of integrated circuits) and does not need to be illustrated in great detail in this context.

Results substantially similar to those illustrated in FIG. 5 and, in particular, FIG. 6, can also be obtained by incision using laser beams, for example, before or after the operation for cutting the stent structure from a blank constituted by a microtube of metal.

As a rule, all of the solutions illustrated in FIGS. 1 to 6, and any equivalents thereto, can apply to stents obtained from a metal microtube, possibly manufactured totally or partly by sintering, as well as stents obtained from a wire, the processes illustrated being performed either before or after cutting the tube and/or winding the wire. For reasons of manufacturing simplicity, the applicant has in any case established that it is preferred to form the surface sculpturing before cutting the tube or winding the wire. 

1. An improved process for producing a stent for angioplasty, said improvement comprising: prior to cutting a microtube, creating on said microtube a plurality of regions configured to contain an active agent; and polishing said stent.
 2. The improved process of claim 1 wherein the step of polishing is performed after the step of cutting.
 3. The improved process of claim 1 in which said cutting further comprises cutting stent structure apertures.
 4. The improved process of claim 1 in which said regions are designed to locally deliver said active agent.
 5. The improved process of claim 1 in which said cutting comprises laser cutting.
 6. The improved process of claim 5 in which said creating comprises use of a laser.
 7. A process comprising, applying to a microtube blank the following sequence of steps: first, creating a plurality of incisions into said blank that are configured to contain an active agent, and second, cutting a stent structure into said microtube blank.
 8. The process of claim 7 wherein the microtube blank has an inner surface and an outer surface defining a thickness therebetween, and wherein the plurality of incisions extend into the outer surface of the tubular blank.
 9. The process of claim 8 wherein the plurality of incisions extend into the outer surface of the tubular blank to a depth which is less than the thickness between the outer surface and the inner surface.
 10. The process of claim 7 further comprising, after said first step, depositing an active agent into the plurality of incisions.
 11. The process of claim 10 in which said active agent is selected from the group consisting of an antithrombogenic agent, an agent for resisting restenosis, and an agent to resist tissue proliferation.
 12. The process of claim 7 further comprising, after said first step, depositing a plurality of active agents into the plurality of incisions.
 13. The process of claim 7 wherein cutting said microtube blank comprises cutting said microtube blank into individual sections.
 14. The process of claim 7 further including a third step comprising polishing a surface of the microtube blank.
 15. The process of claim 7 in which said microtube blank is a metal microtube blank.
 16. The process of claim 7 in which said cutting comprises laser cutting.
 17. The process of claim 16 in which said creating comprises use of a laser.
 18. A process of forming a drug carrying stent from a microtube, the microtube having an exterior surface and an interior surface defining a wall thickness therebetween, the stent having a generally cylindrical structure with a plurality of apertures and a plurality of locations for containing a drug, the apertures having a shape which increases in size when the stent is expanded, the locations for containing a drug having a shape which is substantially unchanged when the stent is expanded, the process comprising: controlling a laser cutting machine to cut both the apertures and the locations for containing a drug into the microtube during a stent forming process; and, polishing a surface of the stent.
 19. The process of claim 18 wherein the microtube has an exterior surface and an interior surface defining a wall thickness therebetween and wherein the locations for containing a drug are cut to a depth which is less than the wall thickness.
 20. The process of claim 18 wherein the locations for containing a drug are cut before the apertures are cut.
 21. The process of claim 18 further comprising: depositing a drug in the plurality of locations for containing a drug, the depositing step being performed in a manner that results in direct contact between the drug and the walls of a vessel in which the stent is deployed.
 22. The process of claim 18 further comprising: depositing a coating in the plurality of locations for containing a drug, the coating being the outermost layer of the stent, the coating comprising an active agent.
 23. The process of claim 18 further comprising: depositing a coating including an active agent in the plurality of locations for containing a drug such that when the stent is deployed at a treatment site in a vessel the coating is in direct contact with a wall of the vessel.
 24. An improved process for producing a stent for angioplasty, said improvement comprising, prior to cutting stent structure apertures into a microtube, creating on said microtube a plurality of regions configured to contain an active agent.
 25. The improved process of claim 24 in which said regions are placed to locally deliver said active agent.
 26. The process of claim 24 in which said cutting comprises laser cutting.
 27. The process of claim 26 in which said creating comprises use of a laser.
 28. A process comprising, applying to a microtube blank the following sequence of steps: first, creating a plurality of regions in said blank sized to contain an active agent, second, cutting said microtube blank, and after said first step, placing said active agent in said plurality of regions.
 29. The process of claim 28 in which said cutting said microtube blank comprises cutting said blank into individual sections.
 30. The process of claim 28 further comprising, after said first step, placing a second active agent in said plurality of regions.
 31. The process of claim 28 in which said active agent is selected from the group consisting of an antithrombogenic agent, an agent for resisting restenosis, and an agent to resist tissue proliferation.
 32. The process of claim 28 further comprising making an inner tubular surface of said blank.
 33. The process of claim 28 further comprising polishing a surface of the microtube blank.
 34. The process of claim 28 in which said microtube blank is a metal microtube blank.
 35. The process of claim 28 in which said cutting comprises laser cutting.
 36. The process of claim 35 in which said creating comprises use of a laser.
 37. A process comprising, applying to a microtube blank the following sequence of steps: first, cutting a plurality of regions into said blank that are configured to contain an active agent; second, cutting a stent structure into said microtube blank; and wherein the process further comprises polishing a surface of the microtube blank.
 38. The process of claim 37 in which said cutting a stent structure into said microtube blank comprises cutting said blank into individual sections.
 39. The process of claim 38 further comprising making an inner tubular surface of said blank.
 40. The process of claim 38 in which said microtube blank is a metal microtube blank.
 41. The process of claim 38 in which said cutting comprises laser cutting.
 42. The process of claim 41 in which said creating comprises use of a laser.
 43. A method of making a medicated stent comprising: providing a tubular body portion having an inner surface and an outer surface and defining a stent thickness therebetween; laser cutting a plurality of incisions in the outer surface of the tubular body portion; after cutting the incisions, laser cutting a plurality of apertures in the tubular body portion extending from the outer surface to the inner surface, the apertures being positioned such that the tubular body portion is expandable from a radially-contracted position to a radially-expanded position; and depositing an active agent in the plurality of incisions.
 44. The method of claim 43 wherein the incisions comprise an incision depth, the incision depth being less than the stent thickness.
 45. The method of claim 43 wherein the active agent is an antithrombogenic agent.
 46. The method of claim 43 further comprising polishing a surface of the tubular body portion after the incisions and apertures are cut.
 47. The method of claim 43 wherein during the step of depositing an active agent in the plurality of incisions the active agent is deposited to a depth which is less than the stent thickness. 